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Presentation on

Life Cycle Assessment of

Portland Cement Manufacturing Process

Presentation

by

Nikhil Kulkarni

Purpose: Internet Based Environmental Management Course, CCE, Indian Institute of Science, Bangalore, India.

Date: 22/12/2010

1

Flow of presentation

• Problem formation

• Objectives

• Cement manufacturing process

• Overview of Life Cycle Assessment

• Methods

• Definition of goal and scope

• Inventory analysis

• Impact assessment of environmental loading

• Evaluation of impact assessment

• Scope for further work

• Conclusions/ Recommendations

• References 2

Problem formation

3

• Concrete is second only to water as the most consumed substance on Earth, with almost one ton of it being used for each human every year on the planet earth. (Lafarge Coppee SA. Globe and Mail, October 20, 2000).

• one of the largest greenhouse gas emitting, highly energy and natural resource consuming industries.

Objectives

• To assess the life cycle of Portland cement manufacturing process to minimize the environmental impact.

4

5



• Objectives



• Methods







• References

Cement Manufacturing Process

Types :

1) Hydro process (Wet process)

2) Pyro process (Dry process)

Considering life cycle of cement, it undergoes

various chemical and physical transformations.

Considering product system:

Inputs: Raw materials and energy (Electricity and

fuel sources)

Outputs: Principal product, Emissions to air, solid

waste, other environmental interactions 6

7

Other raw material

EnergyOther

environmental interactions

Airborne emissions

Water effluents

Solid waste

Crushing

Clinker cooling

Raw material grinding

Lime Stone Mining

Raw meal storage and blending

Stacking and reclaiming

Clinker storage

Preheating and burning

Clinker grinding

Cement storage in silos

Packing and dispatch

Use

Disposal

9

Prehetar section

K -string

Rotary kiln

grate cooler

Riser duct

Coal burner

clinkerCool air by fan

Raw

mate

rial fe

ed

Perhetar fan

200deg tem.

1100 deg tem.

• Cement is an inorganic, non-metallic substance with hydraulic binding properties, and is used as a bonding agent in building materials.

10

Cement Compound

Weight Percentage

Chemical Formula Abbreviated Notation

Tricalcium silicate

50 Ca3SiO5 or 3CaO•SiO2 C3S

Dicalcium silicate 25 Ca2SiO4 or 2CaO•SiO2 C2S

Tricalciumaluminate

10 Ca3Al2O6 or 3CaO •Al2O3 C3A

Tetracalcium aluminoferrite

10 Ca4Al2Fe2O10 or CaO•Al2O3•Fe2O3 C4AF

Gypsum 5 CaSO4•2H2O

Cement Manufacturing Process

Overview of Life Cycle Assessment

11

Life Cycle of product, process, service

12



• Objectives



• Methods







• References

Goaland scopedefinition

Inventoryanalysis

Impactassessment

Interpretation

Product development,improvement

Strategic planning

Public policy

Marketing

Methods

LCA framework and applications (Phases)

Study area

Goal:

• To assess the potential environmental impactdue to cement manufacturing process

• Purpose of this study is for academic programonly but the outcomes and conclusions will bebeneficial for Indian cement industry so as totackle with environmental impacts, energyefficiency and cost effectiveness.

Definition of goal and scope

Scope of the study

• The scope of the project focuses on the raw materialacquisition, processing, and product manufacturingstages i.e. lime stone mining to Cement.

Definition of goal and scope

• Functions of the product system

• Primary function of cement: Used as a bonding agent in building material.

• Functional unit

• As cement industry is a bulk manufacturer industry all the data collection and calculations in this study have been done for per ton basis.

Definition of goal and scope –System boundaries

Fuel

Energy

Infrastructure

Other raw materials

Waste heat

Fugitive dust

Dispatch

UseDisposal

(1) (2) (3) (4)

(5) (6) (7) (8)

(9) (10) (11) (12) (13) 14)

(15) (16) (17) (18)

18



• Objectives



• Methods







• References

Inventory analysis

19

Involves data collection and calculationprocedures to quantify relevant inputs andoutputs of a product system.

• Raw material from mines• water use• Diesel use• Saw dust/ rice husk use• Explosives use• Particulate matter emissions• Gaseous emissions• Heavy metals emissions

Sr.no.

Name of raw material Name of product Consumption of raw material

1 Explosive,( Ammonium Nitrate Fuel Oil @ 100gm/ ton of Lime stone)

Lime stone 89.95 gm/ton

2 Saw dust/ rice husk Lime stone 10.65 gm/ton

3 Diesel Lime stone 0.42 lit/ton> 3 lit/ ton

Inventory analysis

Lime stone mines

Sr.No.

Raw material Consumption of rawmaterial per unit of outputTones/ Tone of Cement

Name of product

1 Lime stone 0.8757

Cement

2 Shale 0.1

3 Iron ore/ Red ochre 0.0181/0.0111

4 Coal 0.0926

5 Gypsum 0.0706

6 Fly ash 0.2931

Inventory analysis

Process plant :

Stack attached to Min. Particulatematter (mg/Nm3)

Max. Particulatematter (mg/Nm3)

Avg. Particulatematter (mg/Nm3)

Raw mill and KilnExhaust

32.4 50.8 41.6

Cooler 46.5 54.9 50.7

Cement mill 38.0 55.6 46.8

Coal mill 46.0 55.6 50.8

LM Crusher 46.1 54.8 50.45

Inventory analysis

Particulate matter analysis of different stacks

• Hazardous waste :

• 78.8 KL in terms of used oil and grease (Lubricants)

• 32.9 KL F.O. sludge from D.G. sets

• Used oil and grease: 0.036 Lit/ ton

• F.O. sludge : 0.015Lit/ ton

Inventory analysis

Water consumption

(Process plant)

• Industrial: 7.96 lakh lits/ day

• Domestic: 4.18 lakh lits/day

Total : 1296213 lit/ day

Water consumption

(Limestone mine)

• Industrial: 77,213 lits/ day

• Domestic: 5000 lits/day

i.e. 185.18 lit/ ton

Inventory analysis

Inventory analysis of Kiln and raw mill exhaust

Parameter

SO2

NO

NO2

NOx

CO

HCL

NH3

PM

TOC

CO2

O2

H2O

HF

C6H6

Hg

Hydrocarbon

Cobalt

Copper

Lead

Manganese

Nickel

Thalium

Vanadium

Zink

Unit

kg/ ton

0.0146744

0.9254828

0.0167089

1.432698

0.6726382

0.0005658

0.0264336

0.0263513

0.011914

514.67345

220.48723

167.53291

ND

ND

1.436E-05

ND

1.41E-05

2.48E-05

2.825E-05

0.0001199

9.616E-06

2.179E-06

ND

4.016E-06

Inventory analysis

26

Emissions ( e.g. CFCs )

Chemical reaction releases Cl, Br

Cl, Br destroy ozoneMidpoint ( Ozon depletion potential ODP )

Less ozone allows increased UVB radiation - Endpoint

Skin cancer

Crop damage

Immune system suppression

Cataracts

Marine life damage

Damage to materials like plastics

Approach:

Impact assessment of environmental loading

• The categories of the environmental problems

a) Resource depletion/Abiotic depletion ADPADPb) Global warming , GWPGWPc) Acidification, APAPd) Photo-oxidant formation, POCPe) Eutrophication, EPEPf) Human toxicity, HTPHTP


Sr. No

Impact name Classification CommonPossibleCharacterizationfactor

Description ofCharacterizationfactor

1 Resource depletion Global RegionalLocal

Resource depletion potential

Kg Sb- eq

2 Acidification RegionalLocal

Acidification potential

kg SO2-eq

3 Eutrophication Local Eutrophicationpotential

kg PO4-eq

4 Greenhouse effect Global Global warming potential

kg CO2-eq

5 Ecotoxicity (no unit) Local----

Multimediamodeling

6 Human toxicity via water,soil, air, and plants

Global RegionalLocal

Human toxicity potential

Multimedia ModelingKg of 1,4,DCBeq




• Objectives



• Methods







• References

• Simple conversion and aggregation:

∑ ×=subs

subssubscatcat esultInventoryRCharFactesultIndicatorR ,

Evaluation of impact assessment

• CO2 contribute to climate change

• Global Warming Potential (GWP): measure for climate change in terms of radiative forcing of a mass-unit of greenhouse gas

Sample calculation:

• 514.6734 kg CO2/ ton of cement

• 1 x 514.6734 = 514.6734 kg CO2 eq

GWP = 1

impact categor

y

category indicator

characterisation factor

category indicator result


ADP GWP AP POCP EP HTP

kg Sb eq/ kgkg CO2 eq/

kgkg SO2 eq/

kgkg C2H4 eq /

kgkg PO4 eq/

kgkg 1,4 DCB

eq/ kgNaptha 0.0201

LPG 0.0187NGL 0.0187Coal 0.0067

Natural Gas 0.0187Petrolium 0.0201Crude oil 0.0201

LNG 0.0187

CO2 1CH4 21

HCF 2800N2O 310SF4 23900Nox 0.7 0.028 0.13 1.2Sox 1 0.048 0.096Dust 0.82HCL 0.088 0.5CO 0.027

COD 0.022

T-P 3.06T-N 750

Phenol 0.00008

Source: Handbook of LCA 2002

Parameter GWP AP POCP EP HTP

SO2 0.014674 0.000704 0.001409

NO

NO2

NOx 1.0028886 0.040116 0.186251 1.719238

CO 0.018161

HCL 4.97904E-05

0.000283

NH3

PM 0.021608

TOC

CO2 514.6735


34

• Graphical presentation of emitted particulate mater based on functional unit.

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

PM

R & K exhaust

Cooler

Cement mill

Coal mill

LM crusherPM

kg

/ to

n o

f cem

en

t


0

0.01

0.02

0.03

0.04

0.05

0.06

PM

R & K exhaust

Cooler

Cement mill

Coal mill

LM Crusher

Hu

man

to

xic

ity p

ote

nti

al

(kg

eq

. 1,4

DC

B)


Sr. no. Impact Category Relative Importance Weight (%)

1 Global Warming 16

2 Acidification 5

3 Eutrophication 5

4 Fossil Fuel Depletion 5

5 Human Health 11

Valuing / Weighting


Scope of further work

• Indian cement industry is one of the most growingindustrial sector.

• India’s per capita cement consumption is belowthan the world average per capita cementconsumption.

• There are many new cement manufacturing unitsand cement grinding units are in progress in India.

• Still the reliable and acceptable LCA are notavailable for specifically Indian conditions.

• The LCAs should be carried out for different typesof cement. The LCA of cement will help to betteruse of natural resources with minimizedenvironmental impact. 37

38



• Objectives



• Methods







• References

Conclusions/ Recommendations

• Enclosing cement mill section and using rubber curtains as a barriers for dust.

• Control the corrosion of different transfer

platforms.

• Provision of dust suction facility at ground level.

39

• 1. Policy Aspects

• A comprehensive norm for cement industry (covering all pollutants, when coal and/or alternate fuels are used.)

• Incentivising the use of wastes as raw materials / fuels.

2. Mining

• Efforts for enrichment of low grade limestone

• Shifting emphasis from environment control to environment protection (using globally accepted decision

making tools like LCA to operational mines.)

• Utilization of biodiesel for quarrying operationsto lower lifecycle emission profiles.


3. Process

• Encouraging cement plants to take up LCA studies voluntarily for continual improvement.

• Waste heat recovery system

4. Use of Alternate Fuel

• National policy to systemize supply on long termbasis for consistent quality waste derived fuel.


5. Product Variation

• Encouraging manufacture of blended cement and incentivising the conversion of OPC grinding facilities to PPC.

• Optimization of supply & distribution of fly ash within a cluster.

• Encouraging production of low energy cement.

• Encouraging creation of additional grinding capacities near demand centers (Split location).

7. Packaging• Policy initiatives to discourage the usage of

packed cement bags for large infrastructureprojects and bulk consumers.

• Encouraging the investments in bulk materialhandling and transport facilities to bring downseepage loss


8. Environmental Good Practices

• Encouraging the cement plants to practice common / strategic sourcing across the cement sector for environmental improvement in a cluster.

• Encouraging creation of a Environmental Data Bank shared sourcing center, (NCB as nodal agency to share experience and technical participation).

• Vijay Kulakarni and Ramachandra, T.V. 2009, EnvironmentalManagement,

• RalphHome, Tim Grant and KarliVerghese, Published by CSIROPublishing, 2009, Life Cycle Assessment – Principles, practices andprospects

• INTERNATIONAL STANDARD IS0 14040, First edition 1997-06- 15,• Jonna Meyhoff Fry, Bryan Hartlin, Erika Wallén, and Simon Aumônier

(Environmental Resources Management Limited), January 2010, FinalReport - Life cycle assessment of example - packaging systems for milk

• Jan R. Prusinski, Medgar L. Marceau and Martha G. VanGeem, LIFECYCLE INVENTORY OF SLAG CEMENT CONCRETE

• Presentations:• U.S. EPA Region X, October 15, 2009, Life Cycle Assessment: Impact

Assessment & Applications, Rita Schenck, IERE• G. Dodbiba, K.Takahashi, T. Furuyama, J. Sadaki, T. Kamo, and T. Fujita,

Life Cycle Assessment: A Tool for Evaluating and Comparing DifferentTreatment Options for Plastic Wastes

• UNEP LCA Training Kit, Module e – Impact assessment, Life CycleAssessment - A product-oriented method for sustainability analysis

• Internet access• www.lcacenter.org• http://www.epa.gov/nrmrl/lcaccess/index.html• http://www.scienceinthebox.com/en_UK/sustainability/lifecycleassessment

_en. html

References

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